Multi-stage wash system for vat polymerization-based 3D printed parts

Abstract

The invention is generally a system for washing off residual resin from objects which are three-dimensionally (3D) printed through a vat polymerization (VP) process. Exemplary systems may include a solvent receptacle, a wash reservoir in fluid communication with the solvent receptacle, and a controller configured to pump a solvent from the solvent receptacle to the wash reservoir for washing off residual resin from a 3D-printed object. Exemplary methods may include pumping a first solution of a plurality of solvent solutions from the solvent receptacle to the wash reservoir, dispersing the first solution onto the 3D-printed object, pumping the first solution from the wash reservoir to the solvent receptacle, pumping a second solution of the plurality of solvent solutions from the solvent receptacle to the wash reservoir, and dispersing the second solution onto the 3D-printed object.

What is claimed is: 
     
       1. A system for washing off residual resin from objects that are 3D-printed through a vat polymerization process, comprising:
 a wash reservoir adapted to enclose a 3D-printed object, the wash reservoir in fluid communication with a solvent receptacle, the solvent receptacle housing a plurality of solvent solutions, wherein the solvent receptacle comprises adjacent tanks for separately holding distinct solutions, and further comprises a quick connect valve for each of the adjacent tanks of the solvent receptacle; 
 a solvent disperser including an agitator and a pump, the agitator adapted to disperse the plurality of solvent solutions onto the 3D-printed object and the pump adapted to facilitate a flow of the plurality of solvent solutions between the wash reservoir and the solvent receptacle; 
 a controller in communication with the solvent disperser, the controller including a set of executable instructions configured to:
 pump a first solution of the plurality of solvent solutions from the solvent receptacle to the wash reservoir; 
 disperse the first solutions onto the 3D-printed object; 
 pump the first solution from the wash reservoir to the solvent receptacle; 
 pump a second solution of the plurality of solvent solutions from the solvent receptacle to the wash reservoir; and 
 disperse the second solution onto the 3D-printed object, 
 
 wherein the controller is further configured to:
 pump the second solution from the wash reservoir to the solvent receptacle; and 
 
 activate the agitator to create an airflow and dry the 3D-printed object; 
 an air flow channel for delivering an air flow from an exterior into an interior of the wash reservoir during an air-dry cycle; and 
 an anti-splashing adapter situated on a top region of the wash reservoir, includes an array of slots configured with a small block at its bottom to prevent the wash solvent from leaking out during the agitation process, and acts as a vent or airway for air circulation during air-drying process. 
 
     
     
       2. The system of  claim 1 , wherein the agitator comprises a propeller adapted to be fully or partially submerged in the first or second solvent solutions pumped into the wash reservoir. 
     
     
       3. The system of  claim 1 , wherein the solvent disperser further comprises a base surrounding the receptacle configured to disrupt a vortex from forming during operation of the agitator. 
     
     
       4. The system of  claim 1 , further comprising a sensor configured to indicate to the controller whether a lid of the wash reservoir is sealed or whether a platform secured inside the wash reservoir is leveled. 
     
     
       5. The system of  claim 1 , wherein the solvent disperser further comprises a rotary seal. 
     
     
       6. The system of  claim 1 , further comprising a sensor configured to indicate to the controller a capacity of the solvent receptacle. 
     
     
       7. The system of  claim 1 , further comprising a removable lid configured to secure a platform of the 3D-printed object within the wash reservoir. 
     
     
       8. The system of  claim 1 , further comprising a removable cage for securing the 3D-printed object within the wash reservoir. 
     
     
       9. The system of  claim 1 , further comprising a resin concentration monitoring module including one or more sensors including optical sensors, density sensors, or pressure sensors, configured to detect a resin concentration inside the solvent receptacle.